CN1311797C - An absorbent article having an insert providing for improved fluid distribution - Google Patents

Abstract

An absorbent article for absorbing fluids and effluents such as urine. In particular, an absorbent garment configured to absorb bodily effluents while also helping to reduce relative humidity within the article's environment to minimize skin-effluent contact and provide reduced unwanted skin hydration. To this end, the absorbent article of the present invention has a front section, a rear section, and an intermediate section connecting the front and rear sections, each section having at least one region or portion. The article comprises: a top sheet having a body-facing surface; a back sheet; absorbent material positioned between the top sheet and the back sheet; an elastic material positioned above the absorbent material and forming at least one contour, said contour forming at least one ramp-like structure; and a vapor barrier layer positioned between the absorbent material and the top sheet, the vapor barrier layer reducing the amount of evaporating moisture exposed to the wearer's skin.

Description

Absorbent article, absorbent composite and diaper with insert

technical field

The present invention relates to absorbent products which, inter alia, improve fluid distribution.

Background technique

Many known diaper configurations employ an absorbent material positioned between a liquid-permeable topsheet and a vapor and liquid-impermeable backsheet. Such backsheets are ideal for preventing liquid soils from running from the absorbent material onto the wearer's garment. Unfortunately, the use of liquid and vapor impermeable backsheets can result in high humidity levels within the diaper during use, which can result in higher levels of skin hydration. The occluded moist environment inside diapers employing such backsheets promotes the growth of microorganisms, including Candida albicans, which undesirably leads to the onset of diaper dermatitis (diaper rash).

Diaper dermatitis afflicts nearly every baby at times during diaper wear. The most severe form of this condition is usually caused by a secondary infection with Candida albicans. Although other factors influence the onset of this fungus, a key factor is dampness within the diaper, which is directly related to the occluded or semi-occluded environment in the diaper area.

To reduce humidity inside diapers, breathable polymer films are used as outer covers for absorbent garments such as disposable diapers. Breathable films are generally microporous to provide the desired level of liquid impermeability and breathability. Other disposable diaper designs have been arranged to provide breathable areas in the form of breathable panels or to provide open areas on otherwise vapor impermeable backsheets to aid in ventilation of the garment.

Conventional absorbent articles such as those described above are not entirely satisfactory. For example, articles employing apertured films or breathable sheets exhibit excessive leakage of liquid from the article, excessively soiling the wearer's undergarment or garment in the apertured area or sheet. Additionally, when the absorbent material of the article is loaded with liquid, the wet absorbent member prevents moisture from escaping from the wearer's skin. Such absorbent garment designs do not maintain a high level of breathability when wet and thus do not sufficiently reduce hydration of the wearer's skin. As a result, the wearer's skin remains prone to rashes, abrasion and irritation.

Although many improvements have been made to conventional absorbent articles, a substantial problem encountered with these articles is the tendency of insulting fluids to pool or concentrate in one or more areas of the article. Sometimes the pooling occurs on the surface of the article, and sometimes the pooling occurs inside the article. In either case, pooling generally occurs within the soiled or targeted area of the article. This pooling in the target or insult area makes the article less susceptible to additional insult, which can affect the leakage and drying performance of the article. Despite the inclusion of wicking materials in some absorbent articles, fluids capable of insulting these articles have a tendency to pool in targeted or insulted areas of the article. In general, traditional absorbent articles benefit (such as leakage and improved dryness) from good and rapid fluid distribution, so that the article, especially the target or insulted area of the article, is more receptive to subsequent insults, such that wearing It is almost impossible for them to be exposed to moisture inside the product.

Contents of the invention

The present invention relates to absorbent articles for absorbing fluids and exudates, such as urine. In particular, the present invention relates to absorbent garments, such as disposable diapers and adult incontinence garments, which are constructed to wick fluid away from soiled and/or target areas of the article and absorb body exudates while also facilitating The relative humidity within the environment of the article is reduced to reduce skin-exudate contact and provide reduced skin hydration.

The present invention relates to an absorbent article having a front section, a back section and a middle section interconnecting the front section and the back section, each section having at least one region or portion, the absorbent article comprising: A topsheet on the surface of the body; a backsheet; an absorbent material positioned between the topsheet and the backsheet; an elastic material positioned between the topsheet and the backsheet and forming at least one contour forming at least one ramp-like structure; A vapor barrier layer positioned between the absorbent material and the topsheet and which reduces the amount of exposure of the wearer's skin to evaporative moisture.

The contour of the elastic material encourages fluid to move from one area of the article to another area of the article. The elastic material can be located in one or more regions of the article, such as the crotch, and the elastic material is usually located in the middle section of the article. In one or more embodiments, an absorbent article may have at least one region that accommodates fewer absorbent members than other regions of the article. Also, one or more areas of the article may be free of absorbent members and it is desirable that the crotch of the article be free of absorbent members. Desirably, there is no or substantially no absorbent member in the area or region where the elastic material is provided. The present invention may also include surge management materials and/or vapor barriers. A surge management material is preferably positioned between the topsheet and the elastic or absorbent material, and a vapor barrier layer is preferably positioned between the absorbent member and the topsheet (or surge, if present) to reduce flow from the absorbent member to the wearer's skin. Or the amount of moisture (e.g. evaporated vapor) that moves in the area between the topsheet and the wearer's skin. Product areas on the elastomeric material are preferably free of vapor barriers.

The present invention also provides an absorbent composite defining a front waist segment, a rear waist segment and an intermediate segment interconnecting the front and rear waist segments, each segment having one or more regions, absorbent The composite comprises: a. a vapor permeable backsheet having a water vapor transmission rate of at least 1000 g/ ^m2 /24hr; b. a liquid permeable topsheet; c. an absorbent body positioned between the backsheet and the topsheet; d. At least one corrugation of elastic material located between the backsheet and the topsheet; e. A vapor barrier layer positioned between the absorbent body and the topsheet.

At least one corrugation has a sufficient height to provide movement of fluid away from a region of the absorbent article and/or to change the fluid profile of the article. Changes in the fluid profile of the article can result in reduced skin-exudate contact and can also result in reduced saturation within the insulted or targeted area. The corrugations are preferably ramps or slopes of material which provide direction of fluid flow to one or more regions of the absorbent article, preferably from the crotch and/or insult area of the article. One or more areas of the article, including the insult or target area of the absorbent article, may also be free or substantially free of absorbent body or material. The disposable article may also include a vapor barrier positioned between the absorbent member or surge layer and the topsheet, which reduces or minimizes the movement of moisture from the absorbent core to the external environment between the absorbent article and the skin of the user. As noted above, areas of the article on the elastomeric material are preferably free of vapor barriers.

The present invention provides a diaper having a front waist section, a rear waist section and a middle section interconnecting the front waist section and the rear waist section, each section having one or more regions, the diaper comprising: a. having at least Vapor permeable outer cover with a water vapor transmission rate of 1000g/m ² /24hr; b. Liquid permeable liner; c. Absorbent located between the outer cover and the liner; d. Located between the outer cover and the liner e. a vapor barrier layer positioned between the liner and the surge management layer; f. an elastic material positioned within the middle section of the diaper and forming a ramp structure.

The elastic material has sufficient height to encourage flow of insulting fluid to one or more other areas of the diaper, thereby changing the fluid profile within the diaper. In at least one embodiment of the diaper, the soiled area of the diaper may be free of an absorbent body.

Description of drawings

With reference to the following detailed description of the present invention and the accompanying drawings, the present invention will be more easily and comprehensively understood, and other advantages will also be clearer. In the accompanying drawings:

Figure 1 typically represents a partially cut-away top plan view of an absorbent article according to one embodiment of the present invention;

Figure 2 representatively represents a cross-sectional view of the absorbent article taken along line 2-2 in Figure 1;

Figure 3 typically shows a partially cutaway top plan view of an absorbent body of an absorbent article according to another embodiment of the present invention;

Figure 4 typically shows a cross-sectional view of the absorbent body taken along line 4-4 in Figure 3;

Figure 5 typically shows the positioning of an example "I" shaped ramp relative to other sections of the diaper;

Figure 6 typically represents a cross-sectional view of the embodiment described in Example 3; and

Figure 7 is a typical representation of the bracket and weights used to test the materials described in the Examples.

definition

As used herein, the following terms have specific meanings unless the context gives a different interpretation or expresses a different meaning; and, unless otherwise specified, the singular generally includes the plural, and the plural generally includes the singular.

As used herein, all percentages, ratios and proportions are by weight unless otherwise indicated.

As used herein, the term "bicomponent fiber" refers to a fiber formed from at least two polymers extruded as a blend through the same extruder. The term "mixture" is defined below. Bicomponent fibers do not have the different polymer components arranged in distinct regions that are relatively constant over the cross-sectional area of the fiber, while the different polymers are usually not continuous along the entire length of the fiber, but usually form at the beginning and end All random fine fibers or proto-fine fibers. Bicomponent fibers are also sometimes referred to as multicomponent fibers. Fibers of this general type are taught, for example, in US Patent No. 5,108,827 to Gessner. Bicomponents and bicomponent fibers are also in the textbook Polymer Blends and Composites, by John A. Manson and Leslie H. Sperling, Plenum Press, a division of Plenum Publishing Corporation of New York, IBSN 0-306-30831-2, 1976 edition, Discussed on pages 273-277.

As used herein, the term "blend" refers to a mixture of two or more polymers, while the term "dopant" refers to a subconcept of admixture which refers to components that are immiscible but have been compatibilized. "Miscible" and "immiscible" are defined as mixtures having positive and negative free energies of mixing, respectively. Furthermore, "compatibilization" is defined as the process of modifying the interfacial properties of immiscible polymer blends in order to form dopants.

As used herein, the term "comprises" and other words derived from the root word "comprises" refer to inclusion or open-ended terms, which enumerate the presence of any specified features, elements, integers, steps, or parts, but do not exclude One or more other features, elements, integers, steps, parts, or groups are present or in addition. Accordingly, the term "comprising" includes the more restrictive terms "consisting essentially of" and "consisting of".

As used herein, the term "conjugate fiber" refers to a fiber formed by extruding at least two polymers from separate extruders and then spun together to form the fiber. Conjugate fibers are also sometimes referred to as multicomponent or bicomponent fibers. Although the conjugate fibers may be monocomponent fibers, the aforementioned polymers are generally different from one another. These polymers are arranged in substantially constant distinct regions across the cross-section of the conjugate fiber and extend continuously along the length of the conjugate fiber. The configuration of such conjugate fibers may be, for example, a sheath/core configuration in which one polymer is surrounded by another, or may be a side-by-side, pie or "islands in the sea" arrangement. Conjugate fibers are described in US Patent 5,108,820 to Kaneko et al., US Patent 5,336,552 to Strack et al., and US Patent 5,382,400 to Pike et al. For bicomponent fibers, the polymers can be maintained in a 75/25, 50/50, 25/75 or any other desired ratio. Fibers may also have shapes as described in U.S. Patent 5,277,976 to Hogle et al. and U.S. Patents 5,069,970 and 5,057,368 to Largman et al., which describe fibers with unconventional shapes, the entire contents of which are hereby incorporated by reference .

As used herein, the term "disposable" includes items that are disposed of after one use and are not intended to be laundered and reused.

As used herein, the term "fabric" refers to all woven, knitted and nonwoven fibrous webs.

The terms "front" and "rear" are used throughout the specification to indicate a relative relationship to the garment itself, rather than to refer to an arbitrary position on the garment when worn by the wearer.

As used herein, the terms "inwardly" and "outwardly" refer to positions relative to the center of the absorbent garment, and in particular, laterally and/or longitudinally toward or away from the longitudinal and transverse center of the absorbent garment.

As used herein, the term "layer", when used in the singular, has a dual meaning of a single element or several elements.

As used herein, the term "liquid" refers to a non-particulate substance and/or material that is capable of flowing and retaining the internal shape of the container into which it is filled or placed.

As used herein, the term "liquid communication" means that a liquid is capable of moving from one layer to another or from one location within a layer to another location within the layer.

As used herein, the terms "longitudinal" and "transverse" refer to their ordinary meanings. When the article is laid flat and fully extended, the longitudinal axis lies within the plane of the article and is generally parallel to a vertical plane that bisects a standing wearer into left and right body halves when the article is worn. The transverse axis lies in the plane of the article generally perpendicular to the longitudinal axis. The articles shown in the figures are longer in the longitudinal direction than in the transverse direction.

As used herein, the term "meltblown fibers" refers to fibers formed by capillary extrusion of molten thermoplastic material through a number of thin, usually circular, dies to form molten strands or filaments. Filaments, entering a converging high velocity stream of usually hot gas (eg, air) that attenuates the filaments of molten thermoplastic material to reduce their diameter, which may be reduced to a microfiber diameter. Thereafter, the meltblown fibers are carried by the high velocity air stream and deposited on a coalescing surface to form a web of randomly dispersed meltblown fibers. This method is disclosed, for example, in US Patent No. 3,849,241 to Butin et al. Meltblown fibers are continuous or discontinuous microfibers, typically less than 10 microns in average diameter, and are usually somewhat sticky when deposited on a coalescing surface.

As used herein, the term "microfiber" refers to small-diameter fibers having an average diameter not greater than about 75 microns, for example, an average diameter of from about 0.5 microns to about 50 microns, or more specifically, microfibers may have an average diameter ranging from about 2 microns to about 40 microns. Another frequently used expression of fiber diameter is denier (or denier), which is defined as grams per 9000 meters of fiber and can be expressed in grams per cubic centimeter by the square of the fiber diameter in microns The density, and then multiplied by 0.00707 to calculate. A lower denier indicates a finer fiber, and a higher denier indicates a thicker or heavier fiber. For example, the diameter of a polypropylene fiber given 15 microns can be converted to denier by multiplying its square by 0.89 grams per cubic centimeter and multiplying by 0.00707. Thus, a 15 micron polypropylene fiber has a denier of about 1.42 (15 ² x 0.89 x 0.00707 = 1.415). Outside the United States, the unit of measurement is usually "tex", which is defined as grams per kilometer of fiber. Tex can be calculated in denier/9.

As used herein, "multilayer laminate" refers to a laminate having multiple layers, for example some of the layers may be spunbond and some of them meltblown, such as spunbond/meltblown/spunbond (SMS) Laminates, among others, are disclosed in U.S. Patent 4,041,203 to Brock et al; U.S. Patent 5,169,706 to Collier et al; U.S. Patent 5,145,727 to Potts et al; to Perkins US Patent 5,178,931 to Timmons et al. and US Patent 5,188,885 to Timmons et al. Such laminates can be laminated by sequentially depositing a first layer of spunbond fabric on a moving forming belt, followed by a layer of meltblown fabric, and finally another layer of spunbond, bonded in the manner described below products. Alternatively, the fabric layers may be manufactured separately, collected in rolls, and joined in a separate bonding step. Such typical fabrics generally have a basis weight of from about 0.1 to 12 osy (6 to 400 gsm), or more specifically from about 0.75 to about 3 osy. Multilayer laminates can also have different numbers of meltblown layers or multilayer spunbond layers in many different configurations and can include other materials like film (F) or coform materials such as SMMS, SM, SFS, etc.

As used herein, "nonwoven" or "nonwoven fabric or web" refers to a web having a structure of individual fibers or tows that are interlayered, but not in the same manner as in a woven fabric. Nonwoven fabrics or webs are formed by a number of processes such as meltblowing, spunbonding, and bonded carded webs. The basis weight of nonwoven fabrics is usually expressed in ounces of material per square yard (osy) or grams per square meter (gsm), and the effective fiber diameter is usually expressed in microns. (Note that to convert from osy to gsm, multiply osy by 33.91).

As used herein, the term "personal care product" or "personal care absorbent product" refers to diapers, training pants, swimwear, absorbent underwear, baby wipes, incontinence products and devices, hygiene wipes, wet wipes, feminine hygiene products , absorbent pads, cadaver pads, veterinary pads, bandages and ties, and the like.

As used herein, the terms "region" or "location" generally refer to a pair of items or materials that are larger or smaller than a section or section and are composed of one or more sections, sections or components. As used herein, the terms "region" or "site" are generally interchangeable.

As used herein, the term "skin" refers to the outermost exposed layer of mammalian dermis or epidermis, which may be a wound.

As used herein, the term "spunbond fibers" refers to filaments formed by extruding molten thermoplastic material from several thin, generally circular capillaries of a spinnerette, and then rapidly reducing the diameter of the extruded filaments. Small-diameter fibers, refer to U.S. Patent 4,340,563 by Appel et al., U.S. Patent 3,692,618 by Dorschner et al.; U.S. Patent 3,802,817 by Matsuki et al.; U.S. Patents 3,338,992 and 3,341,394 by Kinney; US Patent 3,502,763 assigned to Hartman, and US Patent 3,542,615 assigned to Dobo et al. Spunbond fibers are generally non-stick when deposited onto a collecting surface. Spunbond fibers are generally continuous and have an average diameter greater than 7 microns, preferably between about 10 and 20 microns (at least 10 samples).

As used herein, the term "target area" refers to an area or location on a personal care article where a wearer typically discharges insults.

As used herein, a substantially fluid or liquid impermeable material is configured to provide a water head of at least about 60 centimeters (cm), preferably at least about 80 cm, more preferably at least about 100 cm. A suitable technique for determining the hydraulic head value is the hydrostatic pressure test described in detail below.

As used herein, substantially vapor permeable materials are configured to provide a water vapor transmission rate (WVTR) of at least about 100 g/m ² /24hr, preferably at least about 250 g/m ² /24hr, more preferably is at least about 500 g/m ² /24hr. A suitable technique for determining WVTR values is the water vapor transmission rate test described in detail below.

In the remainder of the specification, additional clarifications may be used to qualify these terms.

experiment method

hydrostatic pressure test

Hydrostatic pressure testing is used to measure the liquid barrier properties of materials. Typically, a hydrostatic pressure test determines the height, in centimeters, of a column of water that a material will support before a predetermined amount of water passes through. Materials with higher hydraulic head values exhibit greater resistance to liquid penetration than materials with lower hydraulic head values. The hydrostatic pressure test was performed in accordance with Method 5514 - Federal Test Method Standard 191A.

water vapor transmission test

A suitable technique for determining the WVTR (Water Vapor Transmission Rate) value of a material is as follows. For the purposes of the present invention, 3 inch diameter (76 mm) circular samples were cut from test and comparative material Celguard(R) 2500 (Hoechst Celanese Company). Prepare two or three samples of each material. The test cups used for testing were cast aluminum, flanged, 2 inches deep and had mechanical seals and neoprene gaskets. The test cup is sold under the trade designation Vapometer cup #681 by Thwing-Albert Instrument Company of Philadelphia, Pennsylvania. One hundred milliliters of distilled water was poured into each Vapometer cup, and a single sample of each individual test material and control material was placed across the top open area of the respective cup. Tighten the helical flange to form a seal along the edge of the test cup, exposing a circular area (approximately 30 cm ² open exposure area) of the relevant test material or comparative material to the surrounding environment. The cups were then weighed, placed on a plate, and placed in a forced air drying oven set at 100°F (38°C). This furnace is a thermostatic furnace through which outside air circulates to prevent the accumulation of water vapor inside. A suitable forced air drying oven is, for example, the Blue M Power-O-Matic 60 oven distributed by Blue M Electric of Blue Island, Illinois. After 24 hours, the cups were removed from the oven and weighed. The initial, experimental WVTR value is calculated as follows:

Test WVTR=[(weight in grams lost after 24 hours)×7571]/24(g/m ² /24 hours)

The relative humidity inside the furnace was not intentionally controlled. Under predetermined set conditions of 100°F and ambient relative humidity, the WVTR of Celguard 2500 has been determined to be 5000 g/m ² /24 hours. Therefore, Celguard 2500 was used as a control sample for each test. Celguard 2500 is a 0.0025 cm thick film of microporous polypropylene.

Bench test method

The articles and systems of the present invention were tested using brackets and weights. The brackets used in the experiments were polypropylene and shaped to simulate the curvature of the body of the user, eg an infant. Pressure is applied to the article to simulate the pressure of a baby sitting on the article. Figure 7 shows a typical bracket and weight. The bracket has a width as shown in the figures of 33 cm, is closed at the ends, and has a height of 19.5 cm, with an inner distance between the upper arms of 28 cm and an angle between the upper arms of 60 degrees. The bracket has a 6.5 mm wide slot at the lowest point that extends into the paper along the length of the bracket. Pressure is applied to the second polypropylene element, which is shaped to fit within the first bracket. The top of the bracket has an approximately 3 inch by 2 inch cutout that acts as a means to guide the contamination. A small stub about 1 inch in diameter is placed on top of the bracket to apply weight.

Typically, the material to be tested is placed on a carrier with the top sheet facing up and the back sheet facing the polypropylene carrier. The target zone or crotch is centered over the slit at the lowest point of the bracket. The end of the material rests on the crotch to simulate the product position on the user. The top of the bracket rests on top of the product for a total of 7.5 lbs (one 5 lb weight, approximately 6" diameter, 0.75" thick with a hole approximately 1" diameter in the center, and one 2.5 lb weight, 5" diameter, 0.6 inches thick with a hole about 1 inch in diameter in the center) placed on top of the bracket to apply pressure to the product to simulate the pressure of a child. The top of the bracket is kept level and clamped in place for stability. Contamination is introduced into the product via cutouts in the top bracket. First Stain, 60ml blood bank saline (pH 7.0-7.2, 8.5g/L A.C.S. Grade Sodium Chloride, CAS#7647-14-5 Very Pure Reagent Grade Water, CAS#7732-18-5) using Masterflex A Digi-Staltic(R) 7526-00 pump was introduced into the product with Masterflex 6409-17 tubing (both available from Cole-Parmer Instrument Company, Vemon Hills, IL) connected to a nozzle with a 3 mm orifice. Fouling was introduced at a rate of 15ml/sec. Forty-five (45) seconds after the end of the first insult, a second 60ml saline insult was introduced into the product. The second foulant was introduced at a rate of 15ml/sec. Forty-five (45) seconds after the end of the second insult, a third 60ml saline insult was introduced into the product. A third foulant was also introduced at a rate of 15ml/sec. One minute after the end of the third insult, the material was removed from the carriage and spread flat on the x-ray unit. X-rays the xy plane of the diaper and analyzes the fluid distribution. Before each x-ray exposure, metal rods are arranged over the entire width or transverse direction of the stained spot on the product, so that the stained spot is discernible in the radiograph. The X-ray system works for an exposure time of 5 seconds with a tube voltage of 30Kv and a current of 12mA.

The x-ray system used for the experiments was model 10561 HF 100 (obtained from Tronix Inc. Of 31 Business Park Drive, Branford, Conn. 06045) and was suitably enclosed (ie x-ray room). The x-ray system used BIOSCAN OPTIMATE (version 6.2) software, obtained from Optumus, Inc. Of Ft. Collins, Colorado, to aid in the analysis of fluid distribution.

Detailed ways

The contents of the disposable diaper article, which is suitable for wearing on the lower body of an infant, will be described in detail below. However, it is apparent that the absorbent articles and composites of the present invention are also suitable for use in other types of absorbent articles, such as training pants, swimwear, absorbent undergarments, incontinence products and devices, feminine hygiene products, absorbent pads, bandages, hygiene articles and the like. In addition, the present invention will describe the contents of different configurations. It is to be understood that alternative arrangements of the invention include any combination of such configurations. Therefore, in order to facilitate the understanding and description of the present invention, the diapers of the preferred embodiments are used in no way to limit the protection scope of the present invention.

Absorbent articles and composites of the present invention advantageously exhibit improved fluid distribution, reduced fluid travel times (described in more detail below), and reduced skin contact with exudates compared to conventional absorbent articles. Thus, the wearer of the absorbent article of the various aspects of the present invention may experience reduced skin hydration due to reduced skin contact with exudates and/or evaporative moisture, making the skin less suitable for microbial growth, which results in skin Reduced incidence of irritation and rashes. It has been found that the ability of the absorbent articles of the present invention to exhibit low incidence of skin irritation and rashes on the wearer's skin during use depends, at least in part, on the amount of fluids that come into contact with the wearer's skin. Furthermore, it has also been found that the achievement of this low level of skin irritation and rash depends on the ability of the product to maintain low humidity in the product environment. The relative humidity of the product environment includes not only the product itself, but also the area between the user and the product or product.

Examples of suitable constructions for absorbent articles of the present invention are described below and are schematically illustrated in Figures 1-6, respectively. Figure 1 is a representative plan view of a unitary absorbent article of clothing, such as a disposable diaper 10, of the present invention in a flat, uncontracted state (ie, with all elastic-induced wrinkles and shrinkage removed). Portions of this construction are partially cut away to more clearly show the internal construction of the diaper 10, with the wearer contacting surface of the diaper facing the viewer. Figure 2 typically illustrates a cross-sectional view of the absorbent article taken along line 2-2 of Figure 1 . Referring to Figures 1 and 2, the disposable diaper 10 generally defines a front waist section 12, a rear waist section 14, and an intermediate section 16 interconnecting the front waist section and the rear waist section. The front and rear waist segments comprise the general portion of the article configured to stretch substantially over the wearer's front and rear abdomen, respectively, during use. The intermediate section of the article comprises the general portion of the article configured to extend across the crotch of the wearer between the legs. Those skilled in the art recognize that the size and/or location of the crotch region of an absorbent article may vary depending on whether the product is designed for men, women, or both, and the age of the wearer. Although it is intended that in most embodiments the insult or target area is preferably located within the crotch of the article, it is understood that in some cases or embodiments the insult may occur outside the target or crotch, no disclosure in the disclosure What is in any way to limit the scope of protection of the text, so if that happens, it cannot cover the whole scope.

The absorbent article comprises a vapor permeable backsheet 20, a liquid permeable topsheet 22, and an absorbent body or material 24, such as an absorbent pad or the like, disposed between the backsheet 20 and the topsheet 22. The backsheet 20 defines a length and width which, in the illustrated embodiment, correspond to the length and width of the diaper 10 . The absorbent body 24 generally defines a length and width that are less than the length and width of the backsheet 20, respectively. In this way, an edge portion of the diaper 10, such as an edge section of the backsheet 20, can extend past the terminal edge of the absorbent body 24. As shown in FIG. For example, in the illustrated embodiment, the backsheet 20 extends outwardly past the terminal edges of the absorbent body 24 to form the side and end edges of the diaper 10 . The topsheet 22 is generally coextensive with the backsheet 20, but can selectively cover an area that is either larger or smaller than the area of the backsheet 20 as desired. In use, the backsheet 20 and topsheet 22 are intended to face the garment and the wearer's body, respectively. The absorbent body 24 may also be composed of one or more zoned sections of absorbent material, and may or may not be adjacent to or in fluid communication with other sections. Examples of suitable zoned absorbents include, but are not limited to, those disclosed below in commonly assigned U.S. Patent Application Serial No. 10/026862, entitled "AN ABSORBENT ARTICLE EXHIBITING IMPROVED FLUIDDISTRIBUTION," by Wulz et al. on December 20, 2001 dated application (Attorney Docket No. 16891), the disclosure of which is hereby incorporated by reference in its entirety.

The permeability of the backsheet is selected to enhance the breathability of the absorbent article, thereby reducing hydration with the wearer's skin during use, and not allowing excessive condensation of vapors on the garment-facing surface of the backsheet 20, which would be undesirable. dampen the wearer's clothing.

To provide an improved fit and to help reduce leakage of body exudates from the diaper 10, the diaper side and end edges may be elasticized with suitable elastic members, such as single or multiple elastic strands. Elastic threads can be made from natural or synthetic rubber and can optionally be made heat shrinkable or heat elastic. For example, as typically illustrated in FIGS. 1 and 2 , the diaper 10 may include leg elastics 26 configured to operatively gather and pull the side edges of the diaper 10 to enhance the elasticated legs. A cuff that fits snugly around the wearer's leg to reduce leakage and provide improved comfort and appearance. Similarly, waist elastic 28 may be used to elasticize the end edges of the diaper 10 to provide an elasticized waist. The waist elastic is configured to operatively gather and draw the waist section to provide an elastically comfortable snug fit around the waist of the wearer. In the illustrated embodiment, the elastic members are shown in an uncontracted, stretched state for clarity.

Fastening means, such as hook and loop fasteners 30, are used to secure the diaper to the wearer. Alternatively, other fastening means may be used, such as snap buttons, pins, snaps, adhesive tape fasteners, adhesives, mushroom-loop fasteners or the like.

As mentioned above, illustrated and described with reference to Figures 5 and 6, the absorbent article of the present invention may have an elastic material disposed between the topsheet and the backsheet, wherein the elastic material forms at least one contour which urges fluid to exit a side of the article. A region moves to another region of the artifact. Although most preferred embodiments of the present invention have elastic material located in the crotch portion of the article, it is also contemplated that elastic material may be located in other areas of the article. In one or more embodiments, it may be desirable to have more than one profile or ramp-like structure in an article. Also, while the resilient structure is preferably formed as a ramp-like structure with a smooth or constant slope, it is contemplated that any suitable shape, slope or curvature of resilient material may be included in the definition of a ramp-like structure, including, but not limited to, domes, for example. , table top or similar, thereby enabling the fluid to move to other parts or areas of the article.

It is also desirable that the elastic material be able to substantially retain its shape, or conform to other suitably shaped structures, under the weight of the intended user of the product. That is, in the case of a diaper, the strength or resiliency of the elastic material should be such that it retains or substantially retains its shape, or conforms to other suitable shapes as defined above, under the weight of a baby pressing against the elastic material. Those of ordinary skill in the art will recognize that the degree of material resistance to deformation will vary depending on the size and/or weight of the intended user of the product and the distance from the location of the elastic material. Although materials having or meeting the above properties can be used as the elastic material, it is preferred that the elastic material is breathable. By way of example only, the following materials have been found suitable for use as elasticized treatment foams such as closed cell foams commonly used as packaging materials, bonded carded web surge management materials, or the like. Other suitable materials that may be used as the elastic material include, but are not limited to, elastomers, thermoplastics, open or closed cell foams, or plastic composites. While it is desirable for the elastic material to have some elasticity or resilience in order to provide some comfort to the user as compared to a material without elasticity or resilience, this is not required. Additionally, in some embodiments, it is preferred that the elastic material be such, or treated, that it does not readily absorb fluid or preferably reposition fluid.

As described below, as shown in one or more embodiments of the present invention in Figures 3 and 6, the diapers of the present invention may have one or more regions that contain less absorbent material than other regions of the article. As shown in Figure 3, in one or more embodiments, one or more areas of the article may be free or substantially free of absorbent members. In many embodiments, the insulted or target area of the article is preferably the crotch portion of the article with no or substantially no absorbent member. In another embodiment, preferably at least one contoured or corrugated elastic material is positioned in at least one of the regions with little or no absorbent material.

The diaper 10 may also include other layers between the absorbent body 24 and the topsheet 22 or backsheet 20 . As typically shown in Figures 1 and 2, the diaper 10 may include a ventilation layer or spacer layer 32 positioned between the absorbent body 24 and the backsheet 20 to insulate the backsheet 20 from the absorbent body 24 to improve air circulation and effectively The humidity on the garment-facing surface of the backsheet 20 is reduced. The ventilation layer 32 can also participate in the distribution of the outflow of fluid to the part of the absorbent body 24 which does not directly receive the insult. The diaper 10 may also include a surge management material or layer 34 positioned between the topsheet 22 and the absorbent body 24 to prevent accumulation of fluid exudates and further enhance air exchange and distribution of the fluid exudates within the diaper 10 . In one or more embodiments, surge management layer 34 is preferably free or substantially free of superabsorbents. In alternative embodiments, it may be necessary to provide surge management with increased capacity through the inclusion or use of superabsorbent particles or the like. The present invention may also include a vapor barrier layer. A vapor barrier is preferably positioned between the absorbent member and the topsheet (or surge management portion, if present) to reduce the amount of evaporated moisture to which the wearer's skin is exposed. The vapor barrier layer may be a film, nonwoven, nonwoven/film laminate, foam or the like. Preferably, the vapor barrier is at least partially a breathable film, but may be other suitable breathable vapor barrier known to those skilled in the art. It is also contemplated that the vapor barrier layer may be zoned or selectively applied or positioned in one or more regions of the article.

The diaper 10 can be of various suitable shapes. For example, the diaper may have an overall rectangular shape, a T-shape, or approximately an hourglass shape. In the illustrated embodiment, the diaper 10 has a generally I-shape. The diaper 10 also defines a longitudinal direction 36 and a transverse direction 38 . Other suitable diaper components that may be used in the absorbent articles of the present invention include closure flaps, waist panels, elastic side panels, and the like, which are well known to those skilled in the art.

Examples of diaper configurations suitable for direct application which may include other diaper components suitable for use on the diaper are described in U.S. Patent No. 4,798,603 issued January 17, 1989 to Meyer et al.; 1993 to Bernardin US Patent 5,176,668, published January 5; US Patent 5,176,672, issued January 5, 1993, to Bruemmer et al; US Patent 5,192,606, issued March 9, 1993, to Rroxmire et al; and Hanson et al. US Patent 5,509,915, issued April 23, 1996; the entire disclosure of which is hereby incorporated by reference.

The various components of the diaper 10 are integrally assembled using various types of suitable joining means such as adhesives, sonic bonds, heat bonds or combinations thereof. For example, in the illustrated embodiment, the topsheet 22 and backsheet 20 are assembled to each other and to the absorbent body 24 using a bond line, such as a hot melt pressure sensitive adhesive. Adhesive as a uniform continuous layer of adhesive, a layer of adhesive in a pattern, a spray pattern of adhesive, or an array of individual lines, swirls or dots of adhesive. Similarly, other diaper components such as the elastic members 26 and 28, the fasteners 30, and the ventilation and surge management layers 32 and 34 can be assembled into the diaper article by employing the attachment mechanisms identified above.

As typically illustrated in Figures 1 and 2, the backsheet 20 of the diaper 10 is typically comprised of a substantially vapor permeable material. The backsheet 20 can generally be constructed to be at least water vapor permeable, and can have a water vapor transmission rate of at least about 1000 g/m ² /24 hr, preferably at least about 1500 g/m ² /24 hr. More preferably, it has a water vapor transmission rate of at least about 2000 g/m ² /24hr, and even better has a water vapor transmission rate of at least about 2500 g/m ² /24hr. For example, the backsheet 20 may define a water vapor transmission rate of from about 1000 to about 5000 g/ ^m2 /24hr. Materials having a water vapor transmission rate less than described above generally do not allow adequate amounts of air exchange and undesirably lead to increased levels of skin hydration if no other moisture reducing means is provided within the diaper.

In one or more embodiments, the backsheet 20 is also preferably substantially impermeable to liquids. For example, the backsheet can be configured to provide a hydrohead value of at least about 60 cm, preferably at least about 80 cm, and more preferably at least about 100 cm when subjected to a hydrostatic pressure test. Materials having a hydraulic head value less than the above values undesirably result in breakdown by liquid during use. This liquid breakdown undesirably causes the backsheet 20 to become wet, with a clammy feel during use.

The backsheet 20 can be composed of a suitable material that either directly provides the desired levels of liquid impermeability and breathability described above, or, in the alternative, the material can be modified or treated in some way to provide said levels. In one embodiment, the backsheet 20 may be a nonwoven fibrous web configured to provide a desired level of liquid impermeability. For example, a nonwoven web composed of spunbond or meltblown polymer fibers may optionally be treated with a water repellant coating or laminated with a liquid impermeable, vapor permeable polymer film to provide the backsheet 20. In a particular embodiment of the present invention, the backsheet 20 may comprise a nonwoven web composed of a number of randomly deposited hydrophobic thermoplastic meltblown fibers sufficiently bonded or interconnected to provide substantially vapor-permeable and A substantially liquid-impermeable web. The backsheet 20 may also include a vapor permeable nonwoven layer that is topically coated or configured to provide liquid impermeability in selected areas. Preferably, the backsheet has a water vapor transmission rate of at least about 2500 g/ ^m2 /24hr.

Examples of suitable materials for the backsheet 20 are also described in U.S. Patent 5,482,765, published Jan. 9, 1996, entitled "Nonwoven Fabric Laminate With Enhanced Barrier Properties" by Bradley et al.; by Odorzynski et al. , titled "Absorbent Article Having ABreathability Gradient", US Patent No. 5879341 published on March 9, 1999; the inventor is Good et al., titled "Absorbent Article Having AComposite Breathable Backsheet", US Patent published on December 1, 1998 5,843,056; and US Patent 6,309,736, entitled "Low Gauge Films And Film/Nonwoven Laminates," issued October 30, 2001 to McCormack et al; the entire disclosure of which is incorporated herein by reference.

In a particular embodiment, the backsheet 20 is provided by a highly breathable laminate, particularly a microporous film/nonwoven laminate comprising a spunbond nonwoven laminated to a microporous film. The spunbond nonwoven material comprises filaments of about 1.8 denier extruded from polypropylene or a copolymer of propylene and about 3.5 percent by weight ethylene and defines from about 17 to about 25 grams basis weight per square meter. The films consisted of cast composite films having a calcium carbonate-filled linear low polyethylene microporous core and a blended skin of ethylene vinyl acetate and Catalloy ^™ polypropylene (Catalloy ^™ 357P) having a weight of about 58 g/sq. Basis weight in meters, obtained from Basell (having an office in Wilmington DE). The film is preheated, stretched, and heat treated to create microvoids before being laminated to a spunbond nonwoven. The resulting microporous film/nonwoven laminate substrate has a basis weight of from about 30 to about 60 grams per square meter, and a water vapor transmission rate of from about 3000 to about 5000 g/ ^m2 /24hr. Examples of such film/nonwoven laminates are described in detail in U.S. Patent 6,309,736, entitled "Low Gauge Films And Film/Nonwoven Laminates," issued October 30, 2001 to McCormack et al., the full disclosure of which can be found at This is put forward as a reference.

As typically illustrated in Figures 1 and 2, the topsheet 22 suitably presents a body-facing surface that is compliant, soft-feeling, and non-irritating to the wearer's skin. Also, the topsheet 22 can be less hydrophilic than the absorbent body 24 so as to present a drier surface to the wearer, and can be porous enough for liquids to pass through, thereby allowing liquids to easily penetrate through the thickness. . A suitable topsheet 22 can be made from a wide selection of web materials such as porous foams, reticulated foams, open celled plastic films natural fibers (such as wood or cotton fibers), synthetic fibers (such as polyester, or polypropylene fibers), or a combination of natural and synthetic fibers. The topsheet 22 is adapted to help insulate the wearer's skin from liquids retained within the absorbent body 24 .

Various woven and nonwoven fabrics are used for the topsheet 22. For example, the topsheet may consist of a meltblown or spunbond web of polyolefin fibers. The topsheet may also be a bonded carded web consisting of natural and/or synthetic fibres. The topsheet can consist of a substantially hydrophobic material which can optionally be treated with surfactants or treated to impart the desired level of wettability and hydrophilicity. In a particular embodiment of the present invention, the topsheet 22 comprises a nonwoven spunbonded polypropylene fabric consisting of a web of about 2.2-2.8 denier fibers having a weight per square meter of about 17 grams per square meter. basis weight and a density of about 0.11 g/m3. This topsheet 22 can be the surface that is treated with the surfactant of effective amount, for example accounts for about 0.3% by weight of the surfactant that obtains from Uniqema under the trade mark AHCOVEL BASE N-62 market.

In one embodiment, no surfactant is added to or used in the composite material of the present invention, however, in an alternative embodiment, the liner or topsheet 22 of the diaper 10 may also be treated with a surfactant to facilitate The wettability of the lining, thereby promoting moisture to leave the user's skin surface through wicking action, and improving skin health.

As noted above, in alternative embodiments employing surfactants, the surface of the fabric of the topsheet 36 may be treated with about 0.3% by weight of a surfactant mixture comprising the total amount of surfactant based on the surfactant mixture. A mixture of AHCOVEL BASE N-62 and GLUCOPON 220UP surfactants in a 3:1 ratio by weight. Other possible surfactant classes include MASIL SF19 and DC193 surfactants. AHCOVELBASE N-62 was purchased from Uniqema (a branch of ICI with offices in New Castle, DE) and consisted of a blend of hydrogenated ethyloxygenated castor oil and sorbitan monooleate. GLUCOPON 220UP was purchased from Cognis Corporation and included alkyl polyglycosides. MASIL SF19 and DC193 surfactants were purchased from BASF (Gurnee, IL) and Dow Corning (Midland, MI), respectively. MASIL SF 19 and DC 193 surfactants are typical examples of ethoxylated polyalkylsiloxanes. Surfactants can be applied by any conventional means such as saturation, spraying, printing, roll transfer, slot coating, brushing, internal melt addition, etc. The surfactant can be applied to the entire topsheet 22, or can be selectively applied to specific portions of the topsheet 22, such as the middle section along the longitudinal centerline of the diaper, to provide greater wettability to this section.

As typically illustrated in Figures 1 and 2, the absorbent body 24 of the diaper 10 may suitably comprise a matrix of hydrophilic fibers, such as a web of cellulosic fluff, mixed with particles of superabsorbent material commonly referred to as superabsorbent material. In a particular embodiment, the absorbent body 24 comprises a matrix of cellulosic fluff, such as wood pulp fluff, and superabsorbent hydrogel-forming particles. Wood pulp fibers can be exchanged with synthetic, polymeric, meltblown fibers, or a combination of meltblown and natural fibers. The superabsorbent particles can be substantially homogeneously mixed with the hydrophilic fibers, or can be heterogeneously mixed. Alternatively, the absorbent body 24 may comprise a laminate of a fibrous web and a superabsorbent material or other suitable means for retaining the superabsorbent material in a localized area.

The absorbent body 24 can be of any of various shapes and can be composed of one or more regions or regions which may or may not be in contact with each other. For example, the absorbent core can be rectangular, I-shaped, or T-shaped. Examples of other shapes, orientations, and locations are described in more detail below in commonly assigned U.S. Patent Application Serial No. 10/026862, entitled "AN ABSORBENTARTICLE EXHIBITING IMPROVED FLUID DISTRIBUTION," filed December 20, 2001 by Wulz et al. , the disclosure of which is incorporated herein by reference in its entirety. In general, the absorbent body 24 can be a single layer or, alternatively, can be multi-layered, in which case the absorbent body 24 need not extend the full length and width.

The size and absorbent capacity of the absorbent body 24 should be consistent with the size of the wearer and the liquid loads imposed by use of the absorbent article. Furthermore, the size and absorbent capacity of the absorbent body 24 can vary to accommodate wearers ranging from infants to adults. Additionally, it has been found that for the present invention the density and/or basis weight of the absorbent body 24 can vary.

Examples of superabsorbent materials include, but are not limited to, alkali metal and ammonium salts of poly(acrylic acid) and poly(methacrylic acid), poly(acrylamides), poly(vinyl ethers), horses with vinyl ethers, and alpha-olefins. Maleic anhydride copolymers, poly(vinylpyrrolidone), poly(vinylmorphinone), poly(vinyl alcohol), and mixtures and copolymers thereof. Other polymers suitable for use in such absorbent cores include natural and modified natural polymers such as hydrolyzed acrylonitrile grafted starch, acrylic acid grafted starch, methylcellulose, carboxymethylcellulose, hydroxypropyl Cellulose, and natural gums such as alginates, xanthum gum, locust bean gum, etc. Mixtures of natural and wholly or partially synthetic absorbent polymers may also be used in the present invention.

The superabsorbent or superabsorbent material can be of a wide variety of geometric shapes. As a general rule, superabsorbent materials are preferably in the form of discrete particles. However, the superabsorbent material may also be in the form of fibers, flakes, rods, spheres, needles or the like. Typically, the superabsorbent material is present in the absorbent body in an amount of from about 5 to about 90% by weight of the total weight of the absorbent body 24, preferably at least about 30%, more preferably at least about 50%. For example, in certain embodiments, the absorbent body 24 is constructed of a laminate comprising at least about 50%, preferably at least about 70%, by weight, superabsorbent material, the superabsorbent material Covered by a fibrous web or by other suitable means of retaining the superabsorbent material in the localized area.

An example of a superabsorbent material suitable for use in the present invention is HYSORB(R) P7050 polymer available from BASF, which has offices in Portsmouth, Virginia. Other suitable superabsorbent materials may include, but are not limited to, DRYTECH(R) 2035, which is available from Dow Chemical Co. located in Midland, Michigan, or FAVOR SXM880 polymer, which is available from Stockhausen Corporation having offices in Greensboro, North Carolina. purchased.

As with conventional absorbent articles, due to the thickness of the absorbent body 24 and the superabsorbent or superabsorbent material in the absorbent body 24 of the present invention, the liquid uptake rate of the absorbent body 24 itself may be low, or may not be sufficient to hold liquid Multiple insults of the absorbent body 24 (especially if one or more areas of the article or system are substantially free of absorbent material). To enhance overall fluid intake and air exchange, as typically shown in FIGS. 1 and 2, preferred embodiments of the present invention may also include the aforementioned additional apertured, fluid-permeable surge management material layer 34 . The surge management layer 34 is typically less hydrophilic than the absorbent body 24, and has a operative level of density and basis weight to quickly collect and temporarily retain a surge of liquid, thereby sending the liquid away from its original point of entry and substantially completely The liquid is released to other parts of the absorbent body 24 . This structure can help prevent liquid from pooling and collecting on the portion of the absorbent garment against the wearer's skin, thereby reducing the wearer's feeling of wetness. The structure of the surge management layer 34 also generally enhances air exchange within the diaper 10 .

Various woven and nonwoven fabrics can be used to construct the surge management layer 34 . For example, surge management layer 34 may be a layer comprised of a meltblown or spunbond web of synthetic fibers, such as polyolefin fibers. The surge management layer 34 may also be a bonded-carded-web or an airlaid web composed of natural and synthetic fibers. For example, the bonded-carded-web may be a thermally bonded web bonded with low-melt bonding fibers, powders or adhesives. The web optionally includes a blend of different fibers. For purposes of this disclosure, for purposes of illustration, a surge management layer shall refer to a layer, although the layer of surge material may itself consist of one or more layers of material. The surge management layer 34 may be composed of a substantially hydrophobic material, and the hydrophobic material may optionally be treated with a surfactant or otherwise to impart a desired level of wettability and hydrophilicity. In a particular embodiment, surge management layer 34 comprises a hydrophilic, nonwoven material having a basis weight of from about 30 to about 120 grams per square meter.

For example, in certain embodiments, the surge management layer 34 may comprise a bonded-carded-web, nonwoven fabric comprising bicomponent fibers and defining a total basis of about 83 grams per square meter. Heavy. The surge management layer 34 of this structure can be made of about 60% by weight polyethylene/polyester (PE/PET), sheath-core bicomponent fibers and about 40% by weight monocomponent polyester fibers. A homogeneous blend of the sheath-core bicomponent fibers being about 2 denier fibers, the monocomponent polyester fibers being about 3 denier fibers, and the monocomponent polyester fibers having from about 3.8 to Fiber nominal fiber length of approximately 5.08 cm.

In the illustrated embodiment, the surge management layer 34 is preferably disposed in direct contact liquid communication with the absorbent body 24 . The surge management layer 34 may be operably attached to the topsheet 22 using a conventional adhesive pattern, such as a swirled adhesive pattern. Additionally, surge management layer 34 may be operably attached to absorbent body 24 using a conventional adhesive pattern. The amount of adhesive added should be sufficient to provide the desired degree of adhesion, but low enough to avoid unduly restricting the movement of liquid from the topsheet 22 through the surge management layer 34 into the absorbent body 24 or the second material 25.

The absorbent body 24 is preferably positioned in fluid communication with the surge management layer 34 to receive fluid released from the surge management layer, and to retain and store the fluid. In the illustrated embodiment, the surge management layer 34 comprises a separation layer at least partly on another separation layer comprising the absorber 24 and/or the second material 25, thus forming a bilayer arrangement. The surge management layer 34 serves to quickly collect and temporarily retain expelled fluids, to transport and distribute such fluids from the initial point of contact to other portions of the surge management layer 34, and then to release such fluids substantially completely to the area comprising the absorbent body. 24 in one or more layers.

Surge management layer 34 may be of any desired shape. Suitable shapes include, for example, circle, rectangle, triangle, trapezoid, oblong, dog-bone, hourglass or oval. In some embodiments, for example, the surge management layer may be generally rectangular. In the illustrated embodiment, the surge management layer 34 is coextensive with the absorbent body 24 . However, it is contemplated that in one or more embodiments, the surge management layer 34 may extend beyond only a portion of the absorbent body 24 . Where the surge management layer 34 extends only partially along the length of the absorbent body 24 , the surge management layer 34 may optionally be positioned anywhere along the absorbent body 24 . For example, in some embodiments, the surge management layer 34 may function more effectively when it is biased toward the front waist section 12 of the garment. The surge management layer 34 may also be approximately centered on the longitudinal centerline of the absorbent body 24 .

Other materials suitable for the surge treatment layer 34 are disclosed in U.S. Patent No. 5,486,166 entitled "Fibrous Nonwoven Web Surge Layer For Personal Care Absorbent Articles And The Like" on January 23, 1996 in the name of C. Ellis et al.; U.S. Patent No. 5,490,846 entitled "Improved Surge Management Fibrous Nonwoven Web For PersonalCare Absorbent Articles And The Like", published on February 13, 1996, in the name of Latimer et al., published on November 15, 1994 US Patent No. 5,364,382 for "Absorbent Structure Having Improved Fluid Surge Management And Product Incorporating Same," the disclosures of which are incorporated herein by reference.

As stated above, the subject matter of the disclosure herein relates to absorbent articles, particularly diapers, however, the scope of the present invention is not limited in any way inconsistent with the claims. For example, although not shown, another embodiment of the present invention relates to a composite that defines a front waist segment, a rear waist segment, and an intermediate segment interconnecting the front waist segment and the rear waist segment, Each segment has one or more regions. The system includes a vapor-permeable backsheet defining a WVTR of at least about 1000 g/ ^m2 /24hr; a liquid-permeable topsheet; an absorbent disposed between the backsheet and the topsheet; and disposed between the backsheet and the topsheet at least one corrugation of the elastic material therebetween. At least one corrugation has a sufficient height to allow fluid to flow from a region of the absorbent article and/or to change the fluid profile of the article. Changes in the fluid profile of the article can result in reduced skin-exudate contact and can also result in reduced saturation within the insulted or targeted area. The corrugations are preferably ramps or slopes of material which provide direction of fluid flow to one or more regions of the absorbent article, preferably from the crotch and/or insult region of the article. One or more areas of the article, including the insult or target area of the absorbent article, may also be free or substantially free of absorbent body or material. The disposable article may also include a vapor barrier disposed between the absorbent member or surge management and the topsheet, wherein the vapor barrier reduces or minimizes the passage of moisture from the absorbent core to the external environment between the absorbent article and the skin of the user. exercise. Desirably the backsheet comprises a highly breathable laminate, especially a film/nonwoven laminate. More particularly, the nonwoven portion of the laminate may be a spunbond material. In some embodiments of the invention, the backsheet preferably has a WVTR value of at least about 2500 g/ ^m2 /24hr. It is contemplated that the composite may be a personal care product such as a diaper, training pants, absorbent undergarment, adult incontinence product, feminine hygiene product, sanitary absorbent product or the like.

The present invention also relates to a diaper comprising a vapor-permeable outer cover having a WVTR of at least about 1000 g/ ^m2 /24hr; a liquid-permeable liner; an absorbent body disposed between the outer cover and the liner, the absorbent body positioned In one or more regions of the article; a surge management layer or surge management material between the outer cover and the liner; a vapor barrier between the absorbent body and the liner; and an elastic material. The elastic material is disposed within the midsection of the diaper and has a sufficient height to encourage flow of insulting fluid to one or more other areas of the diaper, thereby changing the fluid profile within the diaper. The vapor barrier is preferably a film designed to help reduce the movement of moisture from the absorbent core into the region between the absorbent article and the skin of the wearer, thereby minimizing or reducing contact with the wearer's skin. Generally, a vapor barrier should not be present in the area of the product over the elastic material. Furthermore, it is preferred that the vapor permeable outer cover is substantially liquid impermeable.

In general, as representatively illustrated in the drawings and described herein, each of the various embodiments of the present invention advantageously provides improved absorbent articles that exhibit a change in the fluid profile of the article and that can exhibit skin-exudates Reduction in exposure and/or reduction in saturation within the fouled or target area. Reduced fluid-skin contact levels promote drier, more comfortable skin and make the skin less prone to microbial growth. As such, it is believed that absorbent articles for the wearer made in accordance with the present invention reduce hydration of the skin, thereby resulting in a reduced incidence of skin irritation and rashes.

The following examples facilitate a more detailed understanding of the invention. Specific materials and parameters are illustrative and do not limit the scope of the invention.

example

Example 1

The test was performed on a disposable diaper having the same general construction as a HUGGIES ^(R) Ultratrim Step 3 diaper (described in more detail below in conjunction with Examples 2 and 3).

In the diapers tested, the backsheet comprised a microporous film/nonwoven laminate comprising a spunbond nonwoven laminated to a microporous film. The spunbond nonwoven comprises filaments of about 1.8 denier extruded from polypropylene and defines a basis weight of about 20 grams per square meter. The film consists of a cast composite film having a calcium carbonate filled linear low polyethylene microporous core and a blended skin layer of ethylene vinyl acetate and Catalloy ^™ polypropylene (Catalloy ^™ 357P) having a thickness of about 58 before stretching. basis weight in grams per square meter. The film is preheated, stretched, and heat treated to create microvoids before being laminated to a spunbond nonwoven. The resulting microporous film/nonwoven laminate substrate had a basis weight of 45 grams per square meter, and a water vapor transmission rate of about 4000 g/ ^m2 /24hr. Examples of such film/nonwoven laminates are described in detail in U.S. Patent 6,309,736, entitled "Low GaugeFilms And Film/Nonwoven Laminates," issued October 30, 2001 to McCormack et al., the full disclosure of which is at This is put forward as a reference.

The absorbent core comprises an upper layer and a lower layer, the upper layer extending from the front edge of the absorbent core to about two-thirds of the total length of the absorbent core. The absorbent core comprises from about 10 to about 11 grams of wood pulp fibers, and from about 10 to about 11 grams of superabsorbent material, thus comprising about 50% by weight wood pulp fibers and about 50% by weight Super absorbent material. The lower layer has a basis weight of about 230 grams per square meter, and the upper layer has a basis weight of about 560 grams per square meter, so as to provide a total basis weight of about 790 grams per square meter in the front section of the absorbent core, and A basis weight of about 230 grams per square meter in the back section of the core. The absorbent core also defines a width in the crotch of about 6.35 centimeters.

The topsheet comprises a nonwoven, spunbond, polypropylene fabric consisting of a web of about 2.2-2.8 denier fibers having a basis weight of about 17 grams per square meter and a density of about 0.11 grams per cubic meter . The surface of this topsheet is treated with an effective amount of a surfactant, such as about 0.3% by weight of a surfactant marketed under the trademark AHCOVEL BASE N-62 from Uniqema.

The surge management layer used in this example comprised a 2.5 osy homogeneously mixed bonded-carded-web consisting of 60% by weight polyethylene/polypropylene (PE/PP) sheath-core bicomponent fibers, Composed of 40% by weight monocomponent polyester fiber, the sheath-core bicomponent fiber has a fiber denier of about 1.5d (ESC215A 1.5 dpf HR6 (available from ES Fibervisions, which has offices in Athens, Georgia) office space) or ESC2151.5 dpf HR6 (available from Chisso Corporation, which has offices in Japan)), a monocomponent polyester fiber with a fiber denier of about 3d (Type 121 Merge35351A or Type 235 Merge X52314 (Both were purchased from KoSa, which has offices in Salisbury, North Carolina)).

The diaper also includes an elasticized leg band assembly along about two-thirds of the length of each longitudinal side of the diaper. The assembly has six (6) strands of elastic material laminated to a breathable, nonwoven fabric layer. The elastic strands consist of LYCRA(R) elastomer aligned along the longitudinal length of the diaper to elasticize and gather the leg cuffs of the diaper. For testing purposes, the elastic leg cuff parts were completely cut off to allow the product to lay flat.

In the design, the target area was determined to be 6 inches from the front of the absorbent pad.

The diaper in Example 1 was unchanged and used as a control for the other Examples.

Example 2

The test was performed on a disposable diaper having the same general construction as the HUGGIES ^(R) Ultratrim Step 3 diaper (described in connection with Example 1). The test diapers were essentially the same as the Ultratrim diapers except that the elastic material was placed within the diapers so that the top or apex of the slope was in the target zone. Closed-cell foam (shock absorbing foam, Office Depot product #510750D) was purchased from Office Depot. The foam was shaped into an "I" shaped slope and covered with grocery store bought plastic wrap (ie Saran Wrap(R)). In the orientation shown in Figure 5, the foam/plastic wrap structure is placed inside the liner and on top of the surge management material in the target area of the diaper. The "I" is tapered in the machine direction (MD) to provide a ramp for fluid to flow down. The slope of the "I" shaped slope is about 30 degrees. The width of the ramp in the transverse direction (CD) is the same as that of the surge management layer (approximately 3 inches). "I" shaped slope design is tested by bench test method. The test results for the materials of Examples 1 and 2 are shown in Table 1 below.

In each instance, fluid distribution was measured using x-rays of the xy plane of the soiled diaper. Table 1 shows the total amount of fluid in the 0.91 cm section of the diaper. When the modified product of Example 2 (with elastic material or slope) was compared with the tested HUGGIES( ^R) Ultratrim, both were tested according to the bench test, at 5.5 cm from the center of the target zone (0 point on the x-axis) The amount of fluid in the area is reduced by 21%.

Example 3

The test was done on a disposable diaper having the same general construction as the HUGGIES ^(R) Ultratrim Step 3 diaper of Example 2. The test diapers were essentially the same as the diapers of Example 2, except that the "I" shaped ramps of Example 2 were replaced with rectangular ramps made of the same resilient foam material and plastic wrap. The rectangular ramp was measured to be approximately 3 inches in CD and 2 inches in MD with a slope of approximately 25 degrees. Another difference to the product of Example 3 is that a piece of absorbent having similar xy dimensions to the rectangular ramps was removed from the target area and replaced with ramps. The ramp is then covered with a 2.5 osy surge management material consisting of 60% by weight polyethylene/polypropylene (PE/PP) sheath-core bicomponent fibers and 40% by weight mono Component polyester fiber, the sheath-core bicomponent fiber has a fiber denier of about 1.5d (ESC215A 1.5 dpf HR6 (available from ESFibervisions) or ESC215 1.5 dpf HR6 (available from Chisso Corporation, available at There are offices in Japan)), the monocomponent polyester fiber has a fiber denier of about 3d (Type 121 Merge 35351A or Type 235 Merge X52314 (both commercially available from KoSa)). The diaper liner then replaces the surge management material and slopes. The resulting structure is similar to that shown in Figure 6. The resulting product was tested according to bench tests, the results of which are shown in Table 2 below and compared with the results of Example 1 as a control.

The results in Table 2 indicate that there is little or no fluid in the cross-section of the target zone containing the elasticized product. When compared to the unaltered control of Example 1, the average reduction in the amount of fluid in the ramp design was within the 5.5 cm region of the center of the target zone (0 point on the x-axis) within the 2 inch cutout area of the target zone About 92%.

The test results of Examples 1-3 show that diapers made according to the present invention generally have improved levels of fluid distribution and reduced saturation in the target zone.

Although various patents and other materials have been set forth herein by reference, the written description should control that there is no inconsistency between the material employed and the material in the written description. Also, although the present invention has been described in considerable detail, it will be apparent to those skilled in the art that various changes and modifications can be made without departing from the essence of the present invention. All such changes and modifications are within the scope of the present invention as defined in the appended claims.

Claims (29)

1. absorbent article, it has front waist section, rear section and makes described front waist section and the interconnective intermediate section of described rear section, and each section has at least one zone or part, and described absorbent article comprises: have towards the top flat on the surface of health; Tergite; Be positioned at the absorbing material between described top flat and the described tergite; Elastomeric material, this elastomeric material are positioned between this top flat and this egative film and form at least one profile, and described at least one profile forms at least one ramped shaped structure; Vapor barrier, this vapor barrier are positioned between this absorbing material and this top flat, and the amount that this vapor barrier makes wearer's skin be exposed to evaporation moisture reduces.

2. absorbent article according to claim 1 is characterized in that, this elastomeric material impels fluid another zone from a regional movement of this absorbent article to absorbent article.

3. absorbent article according to claim 1 is characterized in that a part of described elastomeric material is positioned at the top of described top flat.

4. absorbent article according to claim 1 is characterized in that, described intermediate section part at least comprises crotch portion, and described elastomeric material is positioned at this crotch portion of described absorbent article.

5. absorbent article according to claim 1 is characterized in that described absorbent article also comprises the processing material that shoves, and this processing material that shoves is positioned between described top flat and the described absorbing material.

6. absorbent article according to claim 1 is characterized in that, at least one zone of at least one section of described absorbent article comprises the absorbing material that lacks than another zone of described absorbent article.

7. absorbent article according to claim 1 is characterized in that, the crotch portion of described absorbent article does not establish absorbing material.

8. absorbent article according to claim 1 is characterized in that, in the zone that is provided with described elastomeric material of described absorbent article, this absorbent article is not established absorbing material.

9. absorbent article according to claim 1 is characterized in that this top flat is liquid thoroughly.

10. absorbent article according to claim 1 is characterized in that this tergite is a vapor permeable.

11. absorbent article according to claim 2 is characterized in that, impels a regional movement that fluid leaves described absorbent article to comprise foam-like material, elastomer or plastics synthetic to the described elastomeric material in another zone of absorbent article.

12. absorbent article according to claim 2 is characterized in that, described elastomeric material comprises thermoplastic or opens the chamber or the closed chamber foamed materials.

13. absorbent article according to claim 1 is characterized in that, this absorbent article is the personal care product.

14. absorbent article according to claim 13 is characterized in that, described personal care product is selected from health and absorbs product.

15. absorbent article according to claim 13 is characterized in that, described personal care product is diaper, training pants, absorption underwear, adult incontinence products, health cleansing tissue, feminine hygiene, binder, band or corpse and veterinary's cleansing tissue.

16. one kind absorbs complex, it is limited with front waist section, back lumbar part section and makes this front waist section and the interconnective intermediate section of this back lumbar part section, and each section has one or more zones, and described absorption complex comprises:

A. has 1000g/m at least ²The vapor permeable tergite of the steam permeating rate of/24hr;

B. the top flat of liquid thoroughly;

C. the absorber between described tergite and described top flat;

D. at least one ripple of the elastomeric material between described tergite and described top flat;

E. vapor barrier, described vapor barrier is positioned between this absorber and this top flat.

17. absorption complex as claimed in claim 16 is characterized in that, described at least one ripple has enough height, leaves the motion in the zone of this absorption complex so that fluid to be provided.

18. absorption complex as claimed in claim 16 is characterized in that, described at least one ripple is slope or inclined-plane material, so that the direction of fluid to one or more regional movements of this absorption complex to be provided.

19. absorption complex as claimed in claim 16 is characterized in that, absorber is not established in one or more zones of this absorption complex basically.

20. absorption complex as claimed in claim 16 is characterized in that this intermediate section to small part comprises crotch portion, and this elastomeric material is positioned at this crotch portion.

21. absorption complex as claimed in claim 16 is characterized in that, this absorption complex has crotch portion, does not establish absorber basically in this crotch portion.

22. absorption complex as claimed in claim 16 is characterized in that this tergite comprises the breathable laminated product.

23. absorption complex as claimed in claim 22 is characterized in that, this breathable laminated product is a film/nonwoven thing laminated product.

24. absorption complex as claimed in claim 23 is characterized in that, this non-woven fabric is spunbond thing.

25. absorption complex as claimed in claim 16 is characterized in that this tergite has 2500g/m at least ²The steam permeating rate value of/24hr.

26. a diaper, it has front waist section, back lumbar part section and makes described front waist section and the interconnective intermediate section of described back lumbar part section, and each section has one or more zones, and described diaper comprises:

A. has 1000g/m at least ²The vapor permeable outer covering layer of the steam permeating rate of/24hr;

B. the lining of liquid thoroughly;

C. the absorber between this outer covering layer and this lining;

D. the processing layer that shoves between this outer covering layer and this lining;

E. in shove vapor barrier between the processing layer of this lining and this; With

F. elastomeric material, this elastomeric material are positioned in the intermediate section of this diaper and form ramp structure.

27. diaper as claimed in claim 26 is characterized in that, this elastomeric material has enough height, so that provide stained liquid to flow to one or more other zones of this diaper, thereby changes the fluid profile in the diaper.

28. diaper as claimed in claim 26 is characterized in that, does not establish absorber in the stained zone this diaper, that stained liquid converged.

29. diaper as claimed in claim 26 is characterized in that, described vapor permeable outer covering layer is liquid-tight basically.

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